Removal And Installation

REMOVAL 

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1. Apply alignment index marks to the rear propeller shaft flange and the rear pinion flange.
2. Remove and DISCARD  the bolts (1) holding the rear propeller shaft flange to the rear pinion flange.
3. Separate the rear propeller shaft from the rear pinion flange and secure the shaft to the side.
4. Measure and record pinion turning torque.
5. Using suitable chisel, remove the staking from the pinion nut.
6. Remove the pinion nut.

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7. Using the (special tool #C-452, Puller, Companion Flange) (1), remove the pinion flange (2).

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8. Remove the pinion seal (3) using the (special tool #7794-A, Remover, Seal) (2) and (special tool #C-637, Slide Hammer, Universal) (1).
9. Clean and inspect the sealing surface on the pinion flange, if damaged install a NEW  pinion flange. If the pinion seal bore is damaged it will be necessary to replace the Rear Drive Unit (RDU) assembly.

INSTALLATION 

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1. Install the pinion seal using (special tool #9987, Installer, Seal) (1).
2. Clean the pinion splines, apply Mopar® thread sealant meeting MS- CD95A or equivalent to the splines of the pinion flange.
   NOTE:

   For pinion flange installation 3-5 in. lbs. must be added to the original measured pinion turning torque.

3. Place the pinion flange on the splines of the pinion.

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4. Install a NEW  pinion nut and tighten using (special tool #8979, Wrench, Pinion Flange) (1).
   NOTE:

   Do not over tighten pinion nut. The turning torque must be 3-5 in lbs. more than the turning torque before removal.

5. Measure the pinion turning torque, adding 3-5 in. lbs. to pinion nut measurement that was measured before pinion flange removal.
6. Using a suitable chisel, stake both sides of the pinion nut.

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7. Connect the rear propeller shaft and align the index marks on the rear propeller shaft flange and the rear pinion flange.
   NOTE:

   The bolts that are used to secure the propeller shaft to the RDU input flange MUST be replaced. Do not reuse the bolts/washers.

   NOTE:

   Use of Anti-seize compound is prohibited.

   NOTE:

   Make sure the double washer is flat/flush to the joint housing prior to tightening the bolt to avoid damage to the washer, if damaged replace bolt washer assembly.

8. Install NEW  rear propeller shaft bolts (1) and tighten to the proper torque specifications. Refer to TECHNICAL SPECIFICATIONS .
9. Fill the differential. Refer to FLUID, DIFFERENTIAL, STANDARD PROCEDURE .